Underlayment roofing material with a high coefficient of friction and methods thereof

ABSTRACT

A sheet material (e.g., underlayment roofing material) is disclosed having a high coefficient of friction and being fabricated from at least one structural layer and at least one laminated layer. The structural layer can be constructed of a woven product that can include loom fibers that may be twisted, can include a heavier strain material, and/or can include any material and/or method that creates a raised structure (e.g., raised area, raised line, etc.) in the structural layer&#39;s weave. Subsequently, these raised structures in the structural layer&#39;s weave can create small squares, lines, and/or other designs in the underlayment roofing material that provide increased friction and/or traction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/775,920, filed Mar. 11, 2013, the content of which is incorporated herein by reference in its entirety.

FIELD

The present invention generally relates to a multi-layer underlayment roofing material having at least a portion with a high coefficient of friction.

BACKGROUND

Until the twenty-first century, residential sloped roofs typically received asphalt-saturated felt building paper underlayment that functions as, amongst other things, a secondary weather barrier. Substantially mimicking the attributes of asphalt-saturated felt building paper underlayment, synthetic roof underlayment now available can serve substantially the same function as a secondary weather barrier with better resistance to, for example, tearing, moisture, and/or ultraviolet rays than traditional asphalt-saturated felt building paper underlayment.

Recent natural disasters and subsequent rebuilding efforts have shown the versatility of synthetics as roof underlayment by providing a real-life test environment. By way of example, after several hurricanes ravaged southern coastal areas of the United States, many people were forced out of their damaged homes. At the same time, large numbers of homes required quick roof repair and “drying in” to, amongst other things, minimize further damage due to water intrusion. With limited resources, in some instances, contractors triaged homes by repairing the critical components and installing synthetic underlayment as temporary roofing. Some found that the underlayment performed better than other available materials, e.g., FEMA's blue tarps, and/or did not require removal and discarding when a roofing crew eventually installed shingles.

As noted above, in the past some have used a standard roofing paper that may be made out of a tar paper-type product. Some progress has been made in this area with synthetic underlayment, but the surface of synthetic underlayment can still be slick in certain applications. For example, if the synthetic underlayment gets wet, e.g., from rain or morning dew, the surface of the underlayment can become slippery and present a hazardous condition.

SUMMARY OF THE INVENTION

In exemplary embodiments, a multi-layer underlayment roofing material having a high coefficient of friction can include an at least one structural layer and an at least one laminated layer. The at least one structural layer can be a weave and the weave can include a plurality of raised structures. In exemplary embodiments, the plurality of raised structures can form an at least one design in the multi-layer underlayment roofing material that can provide increased friction and/or traction on at least one of a top or bottom surface of the multi-layer underlayment roofing material.

In exemplary embodiments, the weave of the at least one structural layer can include twisted loom fibers that include at least one heavier strain material.

In exemplary embodiments, the plurality of raised structures form a design that provides a region of increased traction over the structural layer.

In exemplary embodiments, the design can inhibit moisture from collecting on the multi-layer underlayment roofing material.

In exemplary embodiments, the design in the multi-layer underlayment roofing material can be at least one of small squares or lines.

In exemplary embodiments, the at least one laminated layer can be laminated to the at least one structural layer.

In exemplary embodiments, the at least one laminated layer can be laminated to a side of the at least one structural layer and another at least one laminated layer can be laminated to an opposite side of the at least one structural layer.

In exemplary embodiments, laminated between a side of the at least one structural layer and a side of the at least one laminated layer can be an another at least one laminated layer.

In exemplary embodiments, a release liner can be releasably laminated to an at least one surface of the multi-layer underlayment roofing material.

In exemplary embodiments, the plurality of raised structures can be fabricated from ribbon material having a high tensile and/or tear strength. In exemplary embodiments, the ribbon material can be coated with a resin. In exemplary embodiments, a cross-sectional shape of the ribbon material can minimize the size of openings in the weave.

In exemplary embodiments, a material with a substantially high coefficient of friction can be added to the at least one laminated layer and/or the at least one structural layer.

In exemplary embodiments, the at least one laminated layer can include a tacky surface and/or a tacky coating that can increase the coefficient of friction of the multi-layer underlayment roofing material.

In exemplary embodiments, the multi-layer underlayment roofing material can further include an at least one UV treatment.

In exemplary embodiments, the multi-layer underlayment roofing material can further include an at least one mold inhibitor treatment.

In exemplary embodiments, the multi-layer underlayment roofing material can further include an at least one fire retardant treatment.

In exemplary embodiments, the multi-layer underlayment roofing material can further include an at least one low emissivity material that reflects radiant energy.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention will be more fully understood with reference to the following, detailed description when taken in conjunction with the accompanying figures, wherein:

FIG. 1 illustratively depicts underlayment roofing material having a high coefficient of friction used in roofing, in accordance with an exemplary embodiment of the present disclosure;

FIG. 2 illustratively depicts a structural layer of underlayment roofing material, in accordance with an exemplary embodiment of the present disclosure;

FIGS. 3A and 3B illustratively depict laminated layers of underlayment roofing material, in accordance with exemplary embodiments of the present disclosure;

FIG. 4 illustratively depicts underlayment roofing material fabricated from a structural layer and a laminated layer, in accordance with an exemplary embodiment of the present disclosure;

FIG. 5 illustratively depicts underlayment roofing material fabricated from a structural layer, front laminated layer, and back laminated layer, in accordance with an exemplary embodiment of the present disclosure;

FIG. 6 illustratively depicts underlayment roofing material fabricated from a structural layer and a laminated layer and with an additional laminated layer, in accordance with an exemplary embodiment of the present disclosure;

FIG. 7 illustratively depicts underlayment roofing material including adhesive layers with a releasable liner, in accordance with an exemplary embodiment of the present disclosure;

FIGS. 8A and 8B illustratively depict underlayment roofing material including high coefficients of friction on their top side and/or bottom side, in accordance with an exemplary embodiment of the present disclosure;

FIG. 9 illustratively depicts underlayment roofing material including one or more layers having increased UV resistance and/or low emissivity material, in accordance with an exemplary embodiment of the present disclosure; and

FIGS. 10 and 11 illustratively depict underlayment roofing material including a substantially large reflectivity layer, in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

The invention generally relates to a sheet material (e.g., underlayment roofing material) having at least a portion with a relatively high coefficient of friction that is fabricated from at least one structural layer and at least one laminated layer. The structural layer can be constructed of a woven product that can include loom fibers that may be twisted, can include a heavier strain material, and/or can include any material and/or method that creates a raised structure (e.g., raised area, raised line, etc.) in the structural layer's weave. Subsequently, these raised structures in the structural layer's weave can form a surface pattern of spaced squares, spaced lines, and/or other designs in the underlayment roofing material that provide a region of increased friction and/or fraction over the structural layer. Further, a layer can be laminated over the structural layer's weave that can provide further increased friction and/or provide additional traction over the raised structures in the structural layer's weave of the underlayment roofing material.

In exemplary embodiments, the addition of a secondary material and/or feature (e.g., laminated layer, raised areas and/or lines in the structural layer's weave, etc.) can be designed so that water or moisture does not sit, e.g., collect, directly on smooth surfaces thereby making the underlayment roofing material substantially safer to walk on, sit on, kneel on, and/or be placed in any other position which can be associated with the installation of underlayment roofing material, shingles, and/or other finished coverings which can be installed over underlayment roofing material.

In exemplary embodiments, the sheet material disclosed can provide a substantially high coefficient of friction in dry, wet, and/or dusty surface conditions and can be used for a variety of applications including, but not limited to, an underlayment roofing material 100 used on a roof 102 of a house 104 as illustrated in FIG. 1, industrial wrapping material, and/or as a fabric, to name a few. For ease, the sheet material is described and/or illustrated, at times, as underlayment roofing material. This is merely for ease and is in no way meant to be a limitation.

Referring to FIG. 2, in exemplary embodiments, the underlayment roofing material can include a structural layer 200 having high tensile and/or tear strength to deformation and/or at least partial separation when exposed to planar, axial, and/or shear forces. Structural layer 200 may also include one or more ribbons 202 woven therealong so that one or more raised portions of ribbons 202 are exposed on one or both sides of structural layer 200. In embodiments, at least a portion of ribbons 202 may be coated with a material, such as a thermoplastic resin. In this manner, ribbons 202 can provide additional strength and/or protective characteristics to structural layer 200 and/or the underlayment roofing material.

In exemplary embodiments, at least a portion of ribbons 202 can be made from any suitable material, such as, but not limited to, woven polyolefin tapes, non-woven polyolefin, and/or woven or non-woven reinforced membrane substrates such as, but not limited to, polyethylene terephthalate, nylon, and/or glass, to name a few.

In exemplary embodiments, ribbons 202 and/or the other material(s) in structural layer 200 can have any reasonable cross-sectional shape such as, but not limited to, substantially flat or planar, round, square, polygonal, and/or any combination or further separation thereof, to name a few. Further, in exemplary embodiments, ribbons 202 and/or the other material in structural layer 200 can have a cross-sectional shape designed to minimize the size of openings defined by the woven pattern of structural layer 200 and/or increase the coefficient of friction of structural layer 200 and/or the underlayment roofing material.

In exemplary embodiments, a material having a substantially high coefficient of friction (e.g., non-slip material) can be added to ribbons 202 and/or another material in structural layer 200. Further, in exemplary embodiments, such material having a substantially high coefficient of friction added to ribbons 202 and/or another material in structural layer 200 can replace at least one laminated layer of structural layer 200 and/or can be used in conjunction with at least one laminated layer. The material having a substantially high coefficient of friction can be added using any of the techniques disclosed herein and/or any other reasonable technique.

In exemplary embodiments, ribbons 202 and/or any other materials in structural layer 200 can form any reasonable raised structure along portions of structural layer 200 of the underlayment roofing material that can be created from any reasonable weave structure such as, but not limited to, plain weave, twill weave, satin weave, complex computer-generated interlacing, pile fabrics, and/or any combination or separation thereof, to name a few. In embodiments, a raised structure or pattern may be defined along a portion of structural layer 200 in a manner alternative to or additional to the raised portions defined by ribbons 202.

In exemplary embodiments, structural layer 200 can be fabricated using any technique such as, but not limited to, weaving, knitting, lacing, felting, braiding, plaiting, and/or any combination or further separation thereof, to name a few. While structural layer 200 has been described and illustrated as including a woven pattern, it will be understood that, in embodiments, structural layer 200 may have any suitable configuration.

Referring to FIGS. 3A and 3B, in exemplary embodiments, a non-woven laminated layer 300 and/or woven material laminated layer 302 can be attached (e.g., laminated) over the structural layer 200 (FIG. 2). In exemplary embodiments, the laminated layers 300, 302 can be produced and/or attached to other layers using lamination, adhesion, plating, deposition, chemical solution deposition, spin coating, chemical vapor deposition, evaporation, sputtering, spraying, dip-coating, painting, polymer coating, powder coating, paper coating, roll-to-roll coating, and/or any combination or separation thereof, to name a few. At times, the laminated layers 300, 302 are described and/or illustrated as being laminated to another layer. This is merely for ease and is in no way meant to be a limitation.

In exemplary embodiments, woven material laminated layer 302 can be fabricated using any technique such as, but not limited to, weaving, knitting, lacing, felting, braiding, plaiting, and/or any combination or further separation thereof, to name a few.

In exemplary embodiments, the laminated layers 300, 302 can include a tacky surface and/or can be treated with a tacky coating that can, for example, provide additional slip-resistant walking surfaces for the underlayment roofing material. In such embodiments, the laminated layers 300, 302 can be treated with a tacky coating which can be comprised of a number of different materials that remain tacky even when wet such as, for example, ethylene vinyl acetate copolymer.

Referring to FIG. 4, in exemplary embodiments, underlayment roofing material 400 can include either or both laminated layers 300, 302 laminated to sheet-like, flexible structural layer 200 with ribbons defining raised structures therealong to form a composite layer.

Referring to FIG. 5, in exemplary embodiments, an underlayment roofing material 500 can include sheet-like, flexible structural layer 200 with ribbons defining raised structures therealong and laminated between a back (house facing) laminated layer 502 and front (sky facing) laminated layer 504 to form a composite layer.

Referring to FIG. 6, in exemplary embodiments, an underlayment roofing material 600 can include a laminated layer 602 laminated between sheet-like, flexible structural layer 200 with ribbons defining raised structures therealong and the laminated layer 300 to form a composite layer. In exemplary embodiments, laminated layer 602 can be made of a polyolefin or a blend of polyolefin.

In exemplary embodiments, the underlayment roofing material can be fabricated from any number of laminated layers and/or structural layers. For ease, only one or two laminated layers and/or structural layers are, at times, described and/or illustrated. This is merely for ease and is in no way meant to be a limitation.

Referring to FIG. 7, in exemplary embodiments, underlayment roofing material 700 can be self-adhering and/or can include an adhesive layer 702 that can be laminated to the back (house facing) surface of the underlayment roofing material 704 that is fabricated, for example, from a laminated layer (not shown) laminated to a structural layer (not shown). Further, in exemplary embodiments, adhesive layer 702 can include a release liner (not shown) releasably laminated to the back (house facing) surface of adhesive layer 702 to, for example, protect a self-adhering underlayment roofing material 700.

Referring to FIGS. 8A and 8B, in exemplary embodiments, top surface 802 and/or bottom surface 804 of underlayment roofing material 806 can have a sufficiently high coefficient of friction to avoid slippage of a user traversing underlayment roofing material 806 and/or slippage between underlayment roofing material 806 and the deck to which underlayment roofing material 806 may be applied.

Referring to FIG. 9, one or more layers of the underlayment roofing material 900 can be treated to increase UV resistance, thereby allowing extended exposure to solar elements while substantially inhibiting, e.g., reducing, minimizing, or preventing damage to underlayment roofing material 900. One or more layers of underlayment roofing material 900 can be treated with mold inhibitors to inhibit, e.g., reduce, minimize, or prevent, mold growth on underlayment roofing material 900 and/or the immediate surrounding roof area. One or more layers of underlayment roofing material 900 can be treated with a fire retardant compound that can increase fire resistance.

Referring to FIG. 10, in exemplary embodiments, one or more layers of the underlayment roofing material 1000 can be made with low emissivity material to reflect radiant energy, thereby reducing heat absorption of radiant energy transfer into, e.g., roof attic space. In exemplary embodiments, a high reflectivity of a material can mean material which possesses a total solar reflection (ASTM E903-96) of at least 65% and/or at least 85%. This material can be made from, for example, Aluminum Foil, Metalized gold, silver, and/or any other material having a reflectance of over 85%. The underside of underlayment roofing material 1000 can have a reflective material laminated to underlayment roofing material 1000 which can have reflectivity of greater than 85%.

Referring to FIG. 11, in exemplary embodiments, underlayment roofing material 1100 can be made of a reflective surface material layer 1102 which can be attached to (e.g., laminated) laminated layer 300 that can cause the combined reflective surface material layer 1102 and laminated layer 300 to function to substantially inhibit and/or reduce heat transfer through underlayment roofing material 1100. Further, in exemplary embodiments, structural layer 200 can also be laminated to the combined reflective surface material layer 1102 and laminated layer 300 to form a composite layer. Further still, in exemplary embodiments, a non-slip material layer 1108 having a substantially high coefficient of friction can also be applied to structural layer 200.

It will be understood that any of the steps described can be rearranged, separated, and/or combined without deviated from the scope of the invention. For ease, steps are, at times, presented sequentially. This is merely for ease and is in no way meant to be a limitation.

Further, it will be understood that any of the elements and/or exemplary embodiments of the invention described can be rearranged, separated, and/or combined without deviated from the scope of the invention. For ease, various elements are described, at times, separately. This is merely for ease and is in no way meant to be a limitation.

While the various steps, elements, and/or exemplary embodiments of the invention have been outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. The various steps, elements, and/or exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Accordingly, the spirit and scope of the present disclosure is to be construed broadly and limited only by the appended claims and not by the foregoing specification. 

What is claimed is:
 1. A multi-layer underlayment roofing material having a high coefficient of friction, comprising: an at least one laminated layer; and an at least one structural layer having a woven configuration and defining a plurality of raised structures therealong to provide increased friction and fraction on at least one of a top or bottom surface of the multi-layer underlayment roofing material.
 2. The multi-layer underlayment roofing material of claim 1, wherein the at least one structural layer includes twisted loom fibers that include at least one heavier strain material.
 3. The multi-layer underlayment roofing material of claim 1 wherein the raised structures define a surface pattern that provides a region of increased traction over the at least one structural layer.
 4. The multi-layer underlayment roofing material of claim 3, wherein the design of the surface pattern is at least one of spaced squares or spaced lines.
 5. The multi-layer underlayment roofing material of claim 1, wherein the at least one laminated layer is laminated to the at least one structural layer.
 6. The multi-layer underlayment roofing material of claim 1, wherein the at least one laminated layer is laminated to a side of the at least one structural layer and another at least one laminated layer is laminated to an opposite side of the at least one structural layer.
 7. The multi-layer underlayment roofing material of claim 1, wherein another at least one laminated layer is laminated between a side of the at least one structural layer and a side of the at least one laminated layer.
 8. The multi-layer underlayment roofing material of claim 1, wherein a release liner is releasably laminated to an at least one surface of the multi-layer underlayment roofing material.
 9. The multi-layer underlayment roofing material of claim 3, wherein the surface pattern inhibits moisture from collecting on the multi-layer underlayment roofing material.
 10. The multi-layer underlayment roofing material of claim 1, wherein the plurality of raised structures are fabricated from a ribbon material having a high tensile and tear strength.
 11. The multi-layer underlayment roofing material of claim 10, wherein the ribbon material is coated with a resin.
 12. The multi-layer underlayment roofing material of claim 10, wherein a cross-sectional shape of the ribbon material is selected to minimize the size of one or more opening defined by the woven configuration of the structural layer.
 13. The multi-layer underlayment roofing material of claim 1, wherein a material with a substantially high coefficient of friction is added to at least one of the at least one laminated layer and the at least one structural layer.
 14. The multi-layer underlayment roofing material of claim 1, wherein the at least one laminated layer includes at least one of a tacky surface or a tacky coating increasing the coefficient of friction of the multi-layer underlayment roofing material.
 15. The multi-layer underlayment roofing material of claim 1, further comprising an at least one UV treatment.
 16. The multi-layer underlayment roofing material of claim 1, further comprising an at least one mold inhibitor treatment.
 17. The multi-layer underlayment roofing material of claim 1, further comprising an at least one fire retardant treatment.
 18. The multi-layer underlayment roofing material of claim 1, further comprising an at least one low emissivity material that reflects radiant energy.
 19. A multi-layer underlayment roofing material having a high coefficient of friction comprising: an at least one structural layer having a woven configuration defining a plurality of raised structures therealong; and at least one laminated layer, wherein the at least one laminated layer is laminated to a side of the at least one structural layer and another at least one laminated layer is laminated to an opposite side of the at least one structural layer so that the plurality of raised structures form an at least one surface pattern in the multi-layer underlayment roofing material that provides increased friction and traction on at least one of a top and bottom surface of the multi-layer underlayment roofing material.
 20. The multi-layer underlayment roofing material of claim 19 wherein at least one laminated layer includes at least one of a tacky surface or a tacky coating, thereby increasing the coefficient of friction of the multi-layer underlayment roofing material. 